Art of building construction



Oct. 23, 1934.

A. 1'.V cAvEY ART 0F BUILDING CONSTRUCTION Filed Aug. 13. 1931 2 Sheets-Sheet 1 INVENTOR.

BWMTW @uf/YM ATTORNEYS Oct. 23, 1934. A. T. cAvEY ART 0F BUILDING CONSTRUCTION Filed Aug. 13. 19:51

2 Sheets-Sheet 2 INVEN TOR.

A TTORNEY` Patented Oct. 23, 1934 UNITED STATES 1,978,012 ART OF BUILDING CONSTRUCTION Arthur T. Cavey, Cincinnati, Ohio, assignor to Carthage Mills Incorporated, Carthage, Ohio, a

corporation of Ohio Application August 13,

4 Claims.

My invention relates to building construction, and particularly to insulated building construction.

It is an object of my invention to provide an 5 art of building in which panels or sheets of some air-cell fibrous material or other insulating medium are employed for constructing concrete retaining forms, and in which the panels or sheets thereby become an integral part of the structure,

l0 being additionally secured to the concrete if desired. Another object of my invention is to so treat the insulating panels or sheets which are employed to make the forms, that the contact surface thereof will be impervious, or substantially 16 so, to the moisture within the concrete.

I have as one specific object, the use of air-cell material such as asbestos, which not only has insulative properties but which will be fire-proof, so that the danger of fire during the construction 20 period will be minimized, and it is in connection with asbestos panels that the surface protection hitherto mentioned is of especial importance.

In connection with my use of sheet material, which becomes a permanent part of the building,

26 it is my object greatly to economlze in the wooden studding ordinarily employed in such construction work. Another object is the employing of suitable fastening devices tor firmly securing the form material to the concrete prior to the final 30 hardening of the concrete.

The above objects and other structural improvements to which reference will be made in the ensuing disclosure, I accomplish by that certain combination and arrangements of parts of which I have shown a preferred embodiment illustrative of my invention.

Referring to the drawings:-

Figure 1 is a sectional view showing the method of constructing the forms for a floor.

Figure 2 is a sectional view along the lines 2-2 in Figure 1.

Figure 3 is a sectional view of a completed floor showing the form panels secured to the concrete with nails.

Figure 4 is a perspective from beneath of a stud superstructure for supporting a door.

Figure 5 is a perspective view from above of the structure shown in Figure 4. l

Figure 6 is a perspective view showing panels of insulating fibrous material being laid to make the form for supporting a concrete floor.

Figure 7 is a perspective view from above the oor level, showing covered panels and one method of sealing the cracks between the panels of insulative sheeting.

1931, Serial No. 556,863

(Cl. I2-71) In Figures 1 and 2,1 have shown a fragmentary sectional view of a section of the super-structure, and forms for the laying of the floor of a building. The actual form is composed of sheets 1 of aircell insulative material held in position by studding 2, which will ordinarily be suitably braced, as with cross studs 3. The reinforced beams of the floor are formed with pieces la of insulative sheeting held in position with boxing 2a.

Metal bars 4 will be laid in the usual cross weblike formation of form reinforcements for the concrete. To reinforce the supporting beams, ends 4a of the bars are 'extended down into the openings 5, which receive the concrete forming reinforcing beams.

In Figure 3 I have shown a fragmentary section of a completed floor. The studding supporting the sheeting 1 of insulative material has been removed, leaving the concrete 5 to which the sheeting is secured by means of nails 6 or other suitable fastening devices which are driven up into the concrete prior to its complete hardening, when it is in sufficiently soft condition to permit the entry of the fastening devices, but in a condition such that, with further hardening, it will hold the fastening devices firmly in position In the four perspective views shown in Figures 4 to 7, I have shown different stages of complete construction in accordance with my invention. In Figure 4 I have shown studding pieces 2 which support the sheets of insulative material, and cross braces 3 which are held in a rigid position by means of diagonal braces 7 and studs 8.

In Figure 5 I show the super-structure which is shown from underneath with Figure 4, from above. Thus I show the studs 2, cross studs 3, and

- the bars 4 extending down into the opening, which forms the reinforcing beam.

When the super-structure is completed, panels 1 of insulating material, which preferably will have sufficient asbestos therein to be fire-proof, will be laid over the super-structure. Where columns are to be poured, box-like supports 9 are constructed about which sections of the asbestos material, such as are indicated at 1b having cut out portions 1c, are snugly fitted.

In Figure 'l I have shown a completed form or floor, for the pouring of concrete. Asbestos insulation is liable to disintegration from moisture, and for this reason I have provided means for protecting the asbestos panels from the wet concrete. One of these means comprises cementing sheets of waterproof substance, such as a thin asphalt-saturated felt to the panels. A convenient way to accomplish this is to cement to each panel a sheet 10 of felt which is larger in two dimensions than the panel, forming laps 10a, These laps may be-cemcnted over on the next panel with a suitable cement or binder, say hot asphalt, applied with a brush 11 from a container 12.

It is not necessary, however, to cover the paneling with a separate waterproof web. The only requirement is that the asbestos board be temporarily protected from the disintegrating effects of the excess Water in the concrete before it has set. Thus it is possible with entire satisfaction to coat the panels with a binder which will be but partially moisture tight, but which will give the temporary protection desired. This may be done after the panels are in place on the forms, or before,in the latter case, a new product is produced, namely a water resistant panel board. A bituminous or other coating may be employed; but I prefer merely to paint the panel with a soluble silicate such as silicate of soda. in water solution, and allow them to dry in air. This gives a very satisfactory protective coating. The entire panel may be impregnated with silicate, but this is ordinarily both unnecessary and undesirable.

In some cases where the panels are to be subjected continuously to conditions of great humidity, it may be found advantageous. where water resistant types of insulating panels are used, no protection may be found necessary.

It is a feature of my invention that the air-cell asbestos sheeting is permanently secured to the 'concrete to form a permanent part of the structure. If desired, the exposed surface of the sheeting may be suitably coated so that the surface will be hardened. I may employ silicate of soda for this purpose, or other coating materials. Concrete will bond satisfactorily to the silicated surface of panel board.

While the invention is in the art of insulated building construction, it is a feature of the invention that in the provision of asbestos or other suitable air-cell insulating sheeting coated with a substance to make it substantially imperviousto moisture, I have provided a new type of building material.

In the past, in insulating building construction, it has been customary to rst erect forms of usual wooden construction, and then pour the concrete, and, after the forms have been removed, to apply a layer of suitable insulative sheeting. In proceeding, however, in accordance with my invention, much of the cost of the form structure is avoided; and the air-cell sheeting being applied prior to the pouring of the concrete, makes it bind thereto much more satisfactorily, so as to become a built-in part of the structure. As against the cost of building complete cementtight forms, casting a roof, floor or wall in them, allowing it to set, removing the forms, and then applying the insulating panels, in my building Of course,

construction, the panels provide the forms against which the-cement is cast, so that the building member has applied to it during its formation the insulating substance, and building and insulation are an integral unit. In addition to saving the cost of application of the insulating material as a. separate operation, I save in the construction of forms. In ordinary work complete cement-tight forms of wood must be made. In the practice of my invention, while the studs and supporting posts may be substantially the same, the paneling itself forms the decking, and it is only necessary to support or brace it by boards laid across the studs at comparatively widely spaced intervals, depending upon the weight or pressure of concrete which the panels must withstand and the inherent strength of the panels. Beneath oors and roof, these boards need not be nailed at all. Again, the panels, forming the complete decking, protect the boards, studs and other members from the concrete so that they are unmarred and may be re-used for any desired purpose.

Having thus described my invention, what I claim as new and desire to secure by Letters Patent, is:-

1. In the art of insulative building construction the steps which consist in employing fibrous air-cell insulative sheets to construct a form, coating the contact surface of the sheeting to render it substantially impervious to moisture, and then pouring concrete into the form thus made, and leaving said insulative sheets on said concrete.

2. In the art of insulative building construction the steps which consist in employing fibrous air-cell insulative sheets to construct a form, coating the contact surface of the sheeting to render it substantially impervious to moisture, and then pouring concrete into the form thus made, and securing the sheets to the concrete to form a permanent part of the building.

3. In the -art of insulative building construction the steps which consist in employing fibrous air-cell insulative sheeting to construct a form, coating the contact surface of the sheeting with an alkaline silicate to render it substantially impervious to moisture, and then pouring concrete into the form thus prepared and leaving the insulative sheeting on said concrete.

4. 'I'hat process of fastening sheet insulating material to concrete, which consists of constructing a form with the insulating sheets as the deck of the form, coating the material with a substan- 

